personal watercraft - Greenhulk Personal Watercraft Performance Forums

Transcription

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LRRIS
INDUSTRIES Inc.
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1992 • 1998
PERSONAL WATERCRAFT
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SERVICE MANUAL
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Foreword
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This manual is designed primarily for use by Polaris personal watercraft service technicians in a properly
equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and
shop procedures in order to perform the work safely and correctly. The technician should read the text and be
familiar with service procedures before starting the work. Certain procedures require the use of special tools.
Use only the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary importance.
This manual includes procedures for disassembly and reassembly, inspection, maintenance, component identification and unit repair, along with service specifications for all 1992 - 1998 Polaris personal watercraft. A table
of contents is placed at the beginning of each chapter to aid the user in locating specific areas of information.
The alphabetic index at the end of the manual will help the user find specific information quickly.
Care is take"n to ensure that all information in this manual was technically correct at the time of publication. How-- ever, all materials and specifications are subject to change without notice.
Comments or suggestions about this manual may be directed to: Service Publications, Supervisor, Polaris
Industries Inc., 1225 Highway 169 North, Minneapolis, MN 55441-5078.
Technical Training Center
Minneapolis, MN 55441
1992-1998 Personal Watercraft Service Manual (PN 9912201)
Printed in U.S.A.
UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS
Throughout these instructions, important information is brought to your attention by the following symbols:
'&'The Safety Alert Symbol means ATTENTION! BECOME ALERT' YOUR SAFETY IS INVOLVED'
A
DANGER
Failure to follow DANGER instructions will result in severe injury or death to the operator, passenger, bystander
or person inspecting or servicing the watercraft.
A
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the operator, passenger, bystander or person inspecting or servicing the watercraft.
NOTE:
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A CAUTION indicates special precautions that must be taken to avoid minor personal injury, or watercraft or property damage.
A NOTE provides key information to clarify instructions.
Polaris acknowledges the following products mentioned in this manual:
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SPECIAL TOOLS
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Loctite, Registered Trademark of the Loctite Corporation
FLEXLOC, Registered Trademark of SPS Technologies
MityVac, Registered Trademark of Neward Enterprises
Torx, Trademark of Textron
Teflon, Trademark of DuPont
Vortex, Trademark of Ocean Pro
Alemite, Trademark of Alemite Corporation
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Special tools described in this manual may be ordered directly from the Victor Specialty Tool Company.
The toll free order FAX number is 1-800-716-3938 (orders only please). Phone 716-742-1790.
Address:
Victor Specialty Tool Co
66 School St.
Victor, NY 14564
CHAPTER 1
GENERAL INFORMATION
Publication Numbers
1.1
Service Bulletin Index By Bulletin Number .. . . . .. 1.2 - 1.4
Service Bulletin Index By Model. . . . . . . . . . . . . . .. 1.4a - 1.4b
Paint Codes
1.5 - 1.6a
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.7
1.8
Model Specifications 1994 - 1995
1.9 - 1.11
1.12 - 1.14c
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Model Specifications 1998 . . . . . . . . . . . . . . . . . . . .. 1.14d - 1.14e
Standard Torque Specifications
1.15
Decimal Equivalents . . . . . . . . . . . . . . . . . . . . . . . . .. 1.16
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Conversion Table
1.17
Tap Drill Charts
1.18
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19 - 1.20
Service Tips
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Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21 - 1.26
1.27
Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.28
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GENERAL INFORMATION
Publication Numbers
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Watercraft Publication Part Numbers
Year
Model
Model No.
(International)
Owner's
Manual
Parts Book
MicroFiche (Set)
1992
SL650
8924058
9912153
9912292
9913434
1993
SL650
8934058
9912443
9912473
(9913435)
1994
1995
8934070
9912443
9912475
8934170
9912484
9912594
SL650
8944058
9912645
9912699
SL750
8944070
9912645
9912701
SLT
8944170
9912484
9912594
SL650 (SL650 International)
8954058 (1954058)
9912969
9913048
SL650 STD (SL650 STD International)
8954358 (1954358)
9912969/
9913375'
9913292
8954070 (1954070)
9912969
9913052
SLTl50 (SLTl50 International)
8954170 (1954170)
9912993
9913056
SLX780 (SLX780 International)
8954287 (1954287)
9913290
9913395
8964066 (1964066)
9913562
9913563
SLTlOO (SLTlOO International)
8964166 (1964166)
9913287
9913392
8964087 (1964087)
9913551
9913552
8964291 (1964291)
9913557
9913558
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1996
SL750
SLT
SLX780 (SLX780 International)
9913744
SLTl80 (SLTl80 International)
8964588 (1964588)
9913567
9913568
Hurricane (Hurricane International)
8964466 (1964466)
9913572
9913573
SLTX (SLTX International)
8964590 (1964590)
9913577
9913578
SL700
8974071
9913919
9914087
SL700 Deluxe
8974072
9913919
9914087
SLT700
8974572
9914111
9914112
Hurricane
8974473
9913926
9914104
9914091
9914092
9914116
9914117
9913923
9914125
SL780
8974088
SLTl80
8974588
SLX PRO 785
8974978
(9913437)
(9913438)
(9914732)
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1998
9913551
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1997
8964287 (1964287)
(9913436)
SL900
8974091
9914102
9914097
SL1050
8974090
9914096
9914097
SLTX
8974590
9914120
9914121
SLH
8984673
9914731
9914516
9914517
SLTH
8984573
9914731
9914655
9914656
SLXH
8984690
9914731
9914511
9914512
SLTX
8984590
9914731
9914631
9914632
, Addendum
Polaris Industries Inc.
1.1
5/98
GENERAL INFORMATION
Service Bulletin Index
Service/Information Bulletins· 1992
PWC-92-01
1. Driveshaft Coupler Lubrication Interval
2.
Flame Arrestor Intake Cover Sealing on Craft Before Ser. # 00097
3.
Storage Cover Hinges and Insert Bolt Torque
PWC-92-02
Dnveshaft Seal/Bearing Housing Oil Reservoir Tube
PWC-92-03
Engine Oil Injection Line Damage
PWC-92-04
SL 650 Carburetion Setup and Adjustments
PWC-92-05
1.
Paint Codes and Refinishing Procedure for SL 650
2.
SL 650 Cylinder Head Gasket Positioning
3.
Optional Jet Pump Impeller for SL 650
PWC-92-06
SL 650 Engine Cooling System Revision
PWC-92-07
SL 650 Engine Cooling System Check Valve Installation
PWC-92-08
Lanyard Cord Switch Adjustment
PWC-92-09
SL650 Engine Spark Plugs
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PWC-92-10
SL650 Engine Draining Procedures for Cold Weather Storage
Service/Information Bulletins· 1993
Incorrect Ride Plate Installed on Some 1993 SL750 Model Watercraft
PWC-93-02
1992 SL650 Fuel Tank Drop Tube Retaining Cap
PWC-93-03
1992 SL650 Update Kit PN 2200475
PWC-93-04
Lanyard Cord Switch Adjustment
PWC-93-05
1993 Model PWCs with Low Oil Warning Buzzers That Remain On After Oil Tank
Has Been Filled
PWC-93-06
Air Intake Silencer Mounting Bolts
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PWC-93-01
1993 SL650 Model #B934058 (all)
1993 SL750 Model #B934070 through Serial #PLE07000C393
PWC-93-08
PWC-93-09
4/96
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PWC-93-07
1. All 1992 and 1993 SL650 and SL750 Fuel Tank Drop Tube Retaining Cap
2.
Fuel Tank Drop Tube Lines and Clamps
3.
Oil Tank Lower Elbow Fitting Inspection
1.
Speedometer Kit Installation on 1992 SL650 Watercraft
2.
Quick Trim System not Staying in Set Position
3.
Inspection of Oil System, Fuel System Vent Lines and Check Valves
Oil Tank Lower Elbow Fitting Replacement
1.2
GENERAL INFORMATION
Service/Information Bulletins - 1994
PWC-94-01
1. Spark Plug Caps Improperly Installed on the Coil High Tension Leads
2. Insufficient Torque on Cylinder Head Nuts
3. Spark Plug Type Listed Incorrectly in Owner's Manual
PWC-94-02
Retention of the air Intake Duct Drain Hose
PWC-94-03
1. Fiberglass Gel Coat Surface Crazing (Spider Webbing)
2. A Limited Number of 1994 SLTs may need Fiberglass Trimmed from
the area below the rub rails in the rear corners
PWC-94-04
Possible Water Leak on SLT Drive Shaft Through-hull Fitting
PWC-94-05
Engine Cooling Water Inlet Hose
PWC-94-06
1.
2.
PWC-94-07
1994 SLT Seat and Compartment Door Seals
PWC-94-08
Front Seat Latch Plate Wear Into Gel Coat on some 1994 SLTs
PWC-94-09
All 1994 SL650, SL750 & SLT, Fuel Tank Drop Tube Retaining Cap
Exhaust Manifold Fasteners
Prevention of Water Leakage
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1994 SL750 Power Trim Nozzle Fasteners
PWC-94-11
1. 1994 SLT Water Leaks at Steering and Reverse Cable
2. All 1994 Watercraft. Rear Muffler Bracket may wear through water supply hose
PWC-94-12
All 1994 Watercraft. Possible water ingestion through the air intake
PWC-94-13
1994 SLT Fuel Tank Vent Relocation
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PWC-94-10
1994 SLT - Reinforcement Of Driveshaft Through Hull Fitting
PWC-95-02
1994 SLT - Fuel Tank Vent System Update
PWC-95-03
All 1994 Models - Failure Of Vacuum Controlled Fuel Valve
PWC-95-04
1995 SLT - Loose Hose Clamp On Exhaust Cross-Over Hose
PWC-95-05
All 1995 Models - Cracked Or Broken Stems On Fuel Tank Pick-up/Sender Unit
PWC-95-06
All 1995 Models - Defective Oil Tank Fitting
PWC-95-07
All 1995 Models - Kinked Fuel Lines
PWC-95-08
1995 SL650/750 - Incorrect Fuel Line Routing
PWC-95-09
1995 SL650/750 - Loose Front Bumper
PWC-95-10
All 1995 Models - Bilge Siphon Fitting Restricted Or Plugged
PWC-95-11
All 1995 Models - Steering Cable Adjustment Procedure
PWC-95-12
All 1995 Models - Grab Handle Cracking
PWC-95-13
1995 SLX 780 - Intermittent Hard Starting
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PWC-95-01
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1.3
4/96
GENERAL INFORMATION
Service/Information Bulletins - 1995 (Cont.)
PWC-95-14
1995 SL650/SL650 STD - Piston Damage Or Lean Condition At High Throttle Settings
PWC-95-15
All 1992-1995 SL650; SL650 STD; SL750; SLX780 - Improved Seat Seal Kit
PWC-95-16
All 1993-1995 Model Watercraft - Cooling Water Hose Damage
PWC-95-17
1995 SL650 STD; 1995 SLX 780 - Threaded Through Hull Fitting May Loosen
PWC-95-18
All 1992-1995 Model Watercraft - Fuel Valve Restriction May Cause Lean Condition
PWC-95-19
1994 - 1995 SLT 750 - Fuel Cap Cracking
PWC-95-20
All 1995 Watercraft - Improved Steering Cable Retention
PWC-97-05
All 1995-1996 Watercraft Fuel Inlet and Cap Replacement
PWC-96-01
1996 SLT700 - Flywheel Replacement and Cylinder Head Bracket Installation
PWC-96-02
All Except SUSLT 700 - MFD Malfunction
PWC-96-03
SLTX - Temperature Sensors Incorrect Or Missing
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All 1996 PWC - Loose Handgrips
PWC-96-05
1996 SL900 and SLTX - Improved Throttle Response On Initial Acceleration
PWC-96-06
1996 SLT 780 - Steering Cable May Contact The Drive Coupler
PWC-96-07
All 1992-1995 Models; All 1996700,780, & Hurricane Models - Fuel Valve Restriction May
Cause Lean Condition
PWC-96-08
1996 SLTX - Revised Carburetor Jetting For SLTX
PWC-96-09
1996 Hurricane - Loose Engine Mounting Bolts and Air Filter Mounting Studs
PWC-96-10
All 1996 Model Watercraft (Except Hurricane) - Leaks At Bilge Plug
PWC-96-11
1996 SL700; SLT700; Hurricane; SL900; - Oil Pump a-Ring Leakage
PWC-96-12
1996 SL700; SLT700; Hurricane; SL900; SLTX; - Loose Or Broken Cylinder Head Bolts
PWC-96-13
1996 Hurricane - Handlebars May Develop Cracks
PWC-96-14
1996 SL780; SLT780; SLX 780 - Carburetor Hi/Low Screw Settings
PWC-96-15
1996 Hurricane - Hood Seal Replacement
PWC-97-05
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PWC-96-04
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Service Bulletins - 1997
PWC-97-01
1997 SL1050 - Quality Assurance Upgrades To Engine And Pump
PWC-97-02
1997 SLTX - Quality Assurance Upgrades To Engine, Pump, and Compartment Door
PWC-97-03
1997 SLTX Compartment Door Latch Plate Replacement
PWC-97-04
1997 SLX Pro 785 Compartment Door Latch Plate Replacement
PWC-97-05
Service Bulletins - 1998
PWC-98-01
5/98
1998 SLX Pro 785 Cooling Water Outlet Hose Restrictor
1.4
GENERAL INFORMATION
Service Bulletin Index - By Model
, 1996 PWC Bulletin Index By Model
Bulletin #
Model
All 1996 Models
Type
Notes
PWC-96-04
PWC-96-10
PWC-97-05
Service
Information
Service
Loose Hand Grips - All 1996 Models
Leaks At Bilge Plug (Except Hurricane)
Fuel Inlet and Cap Replacement
PWC-96-02
PWC-96-03
PWC-96-04
PWC-96-05
PWC-96-08
PWC-96-10
PWC-96-11
PWC-96-12
Service
Service
Service
Service
Service
Information
Service
Information
Multi Function Display-Erratic RPM / Water Damage
Engine Temp Sensor Incorrect Or Missing
Improved Throttle Response On Initial Acceleration
Revised Carburetor Jetting For SLTX
Oil Pump a-Ring Leakage
Loose Or Broken Cylinder Head Bolts
1996 SLTX
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1996 SL 900
Service
Service
Service
Information
Service
Information
Improved Throttle Response On Initial Acceleration
PWC-96-02
PWC-96-04
PWC-96-07
PWC-96-10
PWC-96-14
Service
Service
Information
Information
Service
Fuel Valve Restriction May Cause Lean Condition
Carburetor High/Low Screw Settings
PWC-96-02
PWC-96-04
PWC-96-06
PWC-96-07
PWC-96-10
PWC-96-14
Service
Service
Service
Information
Information
Service
Steering Cable May Contact Drive Coupler
PWC-96-02
PWC-96-04
PWC-96-07
PWC-96-10
PWC-96-14
Service
Service
Information
Information
Service
1996 SLT780
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1996 SLX 780
PWC-96-02
PWC-96-04
PWC-96-05
PWC-96-10
PWC-96-11
PWC-96-12
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1996 SL780
1.4a
5/98
GENERAL INFORMATION
Service Bulletin Index By Model
1996 PWC Bulletin Index By Model (Cont.)
Model
Bulletin #
Type
Notes
1996 SLT700
PWC-96-01
PWC-96-04
PWC-96-07
PWC-96-10
PWC-96-11
PWC-96-12
Service
Service
Information
Information
Service
Information
Flywheel Replacement And Cyl. Head Bracket
PWC-96-04
PWC-96-07
PWC-96-10
PWC-96-11
PWC-96-12
Service
Information
Information
Service
Information
PWC-96-02
PWC-96-04
PWC-96-07
PWC-96-09
Service
Service
Information
Service
PWC-96-11
PWC-96-12
PWC-96-13
PWC-96··15
Service
Information
Safety Alert
Service
Loose Engine Mounting Bolts And Air Filter Mounting Studs
Handlebars May Develop Cracks
Seat Seal Replacement - 1996 Hurricane
1996 SL700
1996 Hurricane
Model
All 1997 Models
1997 SLTX
Service
Service
Service
Notes
Quality Assurance Upgrades To Engine, Pump, Door
Compartment Door Latch Plate Replacement
Quality Assurance Upgrades To Engine and Pump
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1997 SL1050
1997 SL900
1997 SLT780
1997 SL780
1997 SLT700
1997 SL700/Deluxe
Hurricane
Type
Bulletin #
PWC-97-02
PWC-97-03
PWC-97-01
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1997 PWC Bulletin Index By Model
1998 PWC Bulletin Index By Model
Model
All 1998 Models
1998 SLTX
1998 SLXH
1998 SLH
1998 SLTH
1998 SLX Pro785
5/98
Bulletin #
S-98-01
Type
Service
Notes
Cooling Water Outlet Hose Restrictor
1.4b
GENERAL INFORMATION
Paint Codes
Paint Codes'
Year
Model
Model No.
Color
(See Note Below)
PPG I Ditzler
Polaris
Reference No. Number
1992
1993
SL650
B924058
Bright White (P133)
8520113
2185 / 91473
SL650
B934058
Bright White (P133)
8520113
2185 / 91473
SL750
B934070
Bright White (P133)
Carnation Pink (P189)
8520113
8520121
SL650
B944058
Bright White (P133)
Rubine Red (P182)
8520113
8520129
2185 / 91473
N/A I N/A
2185/91473
N/A I N/A
SL750
B944070
Bright White (P133)
Black Metallic (P177)
8520113
8520106
2185/91473
9000 1 N/A
SLT
B944170
White (Gel Coat Repair Kit)
Caribbean Blue (P196)
2871287
8520133
N/A / 19717
1994
1995
B954058
Rubine Red (P182)
8520129
N/A 1 N/A
SL650 STD
B954358
Bright White (P133)
8520113
2185 / 91473
SL750
B954070
Purple Ve lvet (P194)
8520160
N/A 1 N/A
SLT750
B954170
8520133
N/A / 19717
SLX780
B954287
Bright White (P133)
Rubine Red (P182)
8520113
8520129
8520106
2185 / 91473
N/A 1 N/A
9000 1 N/A
SL700
SLT700
B964066
Bright White (P133)
Lazer Blue (P217)
8520113
8520231
2185 / 91473
N/A 1 N/A
B964166
Bright White (P133)
Purple Velvet (P194)
8520113
8520133
8520160
2185/91473
N/A 119717
N/A 1 N/A
B964466
Bright White (P133)
Porsche Red (P136)
8520113
8520066
2185 / 91473
N/A 172060
Bright White (P133)
Porsche Red (P136)
8520113
8520066
Bright White (P133)
Purple Wave (P214)
8520113
8520230
8520133
2185 / 91473
N/A 172060
2185 / 91473
N/A 152113
N/A / 19717
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Hurricane
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1996
SL650
B964087
SLT780
B964588
SLX780
B964287
Bright White (P133)
Porsche Red (P136)
8520113
8520106
8520066
2185 / 91473
90001 N/A
N/A 172060
SL900
B964291
Bright White (P133)
Porsche Red (P136)
8520113
8520066
2185 / 91473
N/A 172060
SLTX
B964590
Bright White (P133)
Purple Wave (P214)
8520113
8520230
8520133
2185/91473
N/A / 52113
N/A / 19717
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SL780
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*Includes International models
*. Bright White (P133) Is Ditzler #91473 or PPG 2185
NOTE: Order Polaris "P" Number from Midwest Industrial Coatings (612)-934-8252 . Mix as directed.
N/A = Not Available
1.5
4/97
GENERAL INFORMATION
Paint Codes
Paint Codes*
Year
Model
Model No.
Color
(See Note Below)
Polaris
PPG I Ditzler
Reference No. Number.
1997
SL700
B974071
Bright White (P133)
Lazer Blue (P217)
8520113
8520231
2185 / 91473
N/A 1 N/A
SL700 Deluxe
B974072
Bright White (P133)
Teal Metallic (P168)
8520113
8520199
2185 / 91473
4300 1 N/A
SLT700
B974572
Bright White (P133)
Lazer Blue (P217)
8520113
8520231
2185 / 91473
N/A 1 NlA
Hurricane
B974473
Bright White (P133)
Porsche Red (P136)
Screamin Yellow (P216)
8520113
8520066
8520242
2185 / 91473
N/A 172060
N/A 1 NIA
SL780
B974088
Bright White (P133)
Wild Grape (P237)
8520113
2185 / 91473
SLT780
B974588
-
-
N/A I N/A
8520113
2185 / 91473
N/A 1 N/A
Bright White (P133)
Wild Grape (P237)
-
B974091
Bright White (P133)
Violet Metallic (P242)
8520113
8520249
2185 /9 1473
SL 1050
B974090
Bright White (P133)
8520113
8520242
8520106
2185 / 91473
N/A 1 N/A
90001 N/A
Bright White (P133)
Violet Metallic (P242)
8520113
8520249
2185/91473
N/A 1 N/A
SLTX
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SL900
B974590
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N/A / NI.A.
** Bright White Is Ditzler #91473 or PPG 2185
NOTE: Order Polaris "P" Number from Midwest Industrial Coatings (612)-934-8252 . Mix as directed.
N/A = Not Available
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Gel Coat Repair Kits - For repair of gel coat on fiberglass hulls and decks.
White - 2871287
Caribbean Blue - 2200735
Paint - Top Coat / Metallic
Coatin~
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All Models
Clear Topcoat with Sparkle Metallic powder. Order direct from Midwest Industrial
(612-934- 8252). Mix as directed .
~
2-Part Structural Adhesive - For repair of SMC hulls and decks.
SMC repair kits containing 3MTM #08101 structural adhesive are available in two sizes. This 2-part structural
adhesive is recommended for bonding and general repair of SMC hulls and decks.
2 Oz. - 2871520
4/97
1 Quart - 2871519
1.6
GENERAL INFORMATION
Paint Codes
Paint Codes*
Year
Model
Model No.
Color
(See Note Below)
PPG I Ditzler
Number
1998
SLH
B984673
Bright White (P133)
PWC Violet (P250)
2185/91473
N/A 1 N/A
SLTH
B984573
Bright White (P133)
Dark Cloissone Non Metallic (P252)
2185/91473
N/A 1 N/A
SLXH
B984690
Bright White (P 133)
2185/91473
N/A 1N/A
SLTX
B984590
Bright White (P133)
PWC Violet (P250)
2185/91473
N/A 1 N/A
** Bright White Is Ditzler #91473 or PPG 2185
NOTE: Order Polaris "P" Number from Midwest Industrial Coatings (612)-934-8252. Mix as directed.
NIA = Not Available
Gel Coat Repair Kits - For repair of gel coat on fiberglass hulls and decks.
Caribbean Blue - 2200735
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White - 2871287
Paint - Top Coat I Metallic
All Models
Clear Topcoat with Sparkle Metallic powder. Order direct from Midwest Industrial Coatings
(612-934- 8252). Mix as directed.
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2-Part Structural Adhesive - For repair of SMC hulls and decks.
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SMC repair kits containing 3MTM#08101 structural adhesive are available in two sizes. This 2-part structural
adhesive is recommended for bonding and general repair of SMC hulls and decks.
2 Oz. - 2871520
1 Quart - 2871519
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1.6a
5198
GENERAL INFORMATION
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5/98
1.6b
GENERAL INFORMATION
Model Identification
Identification Numbers
The engine 1.0. number and hull 1.0. number are used to register the watercraft. They are unique numbers that
distinguish each watercraft from others of the same model.
If the watercraft is ever stolen these numbers will help identify it. The owner should keep a record of these
numbers in a place other than the watercraft.
Month Code: A
= January; B = February; etc.
Year Of Manufacture: 5 = 1995; 6 = 1996; etc.
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All SLT Models and Hurricane
All SL and SLX Models
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Starter Cover
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Engine 1.0. Number
(Polaris / Fuji Engine)
Engine 1.0. Number
(Polaris Domestic Engine)
All 650, 750, 780 Models
All 700, 900, 1050, Models
1.7
4/97
GENERAL INFORMATION
Model Specifications
Polaris resarves the right to change specilications at
any time without Incurring obllgatlona.
1992 SL650 8924058
1993 SL650 8934058
1993 SL750 8934070
Dimensions/Materials
Length (inches)
.
Width (inches) ............•............ .
105.5"
105.5"
105.5"
45"
45 "
45"
Height (inches)
.
37.5"
37.5"
37.5"
Draft (stationary, unloaded in inches)
.
9
9
9
Dry Weight (Ibs.)
.
510
495
499
Hull Material
.
Sheet Molded Compound
(SMC)
(SMC)
(SMC)
Top Deck Material .... .. .. .. . .• .. . .. .....
SMC
SMC
SMC
Side Rail Material
.
PVC
PVC
PVC
Front Bumper Material .. . .....•. .. .•.. .. .
TPO
TPO
TPO
Base Color
.
White
White
White
Accent Colors
.
Hot Pink, Blue, Gray
2 person/40;) Ibs.
Capacities
Rider Capacity
.
2 person/400 Ibs.
2 person/400 Ibs.
Front Storage Capacity (cubic feet)
.
1.03
1.03
1.03
Rated Fuel Capacity including reserve
.
9.8
9.8
9.8
Fuel Reserve (U.S. gallons)
.
2.5
2.5
2.5
3.5
3.5
3.5
Engine
be
Oil Reservoir Capacity (U .S. quarts)
Engine Model No. .
.
EC65PW/01
EC65PW01
EC75PW01
Oil Type
.
Polaris Injection Oil or
NMMA Certified TC-W3
Engine Cooling
.
Liquid, open system
Liquid, open system
er
Engine Cylinders
.
3
.
.
Liquid, open system
3
647cc
647cc
744cc
65mmx 65mm
65mm x 65mm
69.72mm x 65mm
Compression Ratio ... . ... . ••. ........ • ..
6.4 to 1 (corrected)
Timing Degrees BTDC
24 ° at 3000 rpm
18° at 3000 rpm
16° at 3000 rpm
Ignition System ... .. .......•. .... . .. . . ..
COl, Flywheel Magneto
Lubrication
.
Oil Injected
Oil Injected
Oil Injected
Horsepower
.
68 HP@6500 rpm
68 HP @ 6500 rpm
78 HP @ 6500 rpm
Maximum Static Thrust (Ibs.)
.
Approximate 550
Approximate 550
Approximate 550
Maximum Torque
.
58 ft./Ibs. @ 6000 rpm
62 ft.llbs. @ 5750 rpm
72.5 ft.llbs . @ 5500 rpm
Carburetion Intake
.
Reed Valve
Carburetors
.
3-38mm, 34mm venturi
Engine Displacement
Bore & Stroke
.
da
3
rt
Carburetlon
Reed Valve
Reed Valve
Electrical
Alternator Output
.
120 watt at 4500 rpm
Spark Plug Type
.
NGK BR8ES, Champion
RN-3C
NGK BR8ES, Champion
RN-3C
NGK BR8ES, Champion
RN-3C
Spark Plug Gap (inches) .... .. .. . • . .. ..•.
.028"
.028 "
.028"
Idle RPM (in water)
1550
.
± 100 rpm
1300
± 100 rpm
1300
± 100 rpm
Propulsion
Jet Pump Type
.
Single Stage Axial Flow
Impeller Rotation
.
Counter Clockwise
Counter Clockwise
Counter Clockwise
Impeller Type
.
Stainless sleel, 3 blade
Stainless steel, 3 blade
Slainless sleel , 3 blade
Impeller Pitch (degrees)
.
14.5° (13/15°)*
15/18°
17/20°
Bilge Pump Type
.
Siphon 2 GPM
Siphon 2 GPM
Siphon 2 GPM
.
74 Decibels
74 Decibels
74 Decibels
DB Noise Level
• 2nd Production
4/96
1.8
GENERAL INFORMATION
1994 SL650 8944058
1994 SL750 8944070
1994 SLT750 8944170
105.35"
44.86 "
37.5"
105.35"
44 .86"
37.5"
120.3"
47.3"
37.0"
9
9
8
495
Modified V
(SMC)
SMC
PVC
TPO
White
Rubine Red 1 Purple
499
Modified V
(SMC)
SMC
PVC
TPO
White
Rubine Red 1 Black
530
Full V
Polyester/glass/foam
composite
Polyester/glass composite
PVC
TPO
White
Caribbean Blue 1Magenta
2 person/400 Ibs.
1.03
9.8
2.5
3.5
2 person/400 Ibs.
1.03
9 .8
2.5
3.5
3 person/500 Ibs.
1.2
11
2.5
EC75PW02
Liquid. open system
EC75PW02
Liquid, open system
3
3
3
647cc
65mmx 65mm
10.7:1
18° at 3000 rpm
68 HP @6350 rpm
Oil Injected
744cc
69.72mm x 65mm
10.7:1
25° at 3000 rpm
80 HP @ 6150 rpm
Oil Injected
744cc
69.72mm x 65mm
10.7:1
25° at 3000 rpm
80 HP @ 6250 rpm
Oil Injected
.
.
Reed Valve
Reed Valve
3-38mm. 34mm venturi
Reed Valve
Ignition System
.
CDI, Flywheel Magneto
Alternator Output
.
Spark Plug Type
Spark Plug Gap (inches)
.
.
10 Amps 1 120 watt at 4500
RPM
NGK BPR 7ES
.028"
Digital CDI , Flywheel
Magneto
10 Amps 1 120 watt at 4500
RPM
NGK BPR 7ES
.028 "
Digital CDI , Flywheel
Magneto
10 Amps 1120 watt at 4500
RPM
NGK BPR 7ES
.028"
Single Stage Axial Flow Polaris
Counter Clockwise
Progressive pitch, Stainless
steel, 4 blade PN 5131079
Counter Clockwise
Standard
Warning Light
Warning Light
Siphon 2 GPM
N/A
N/A
Standard
Standard
Warning Light
Warning Light
Siphon 2 GPM
N/A
N/A
Standard
PolarIs resarves the right to chang a specifications at
Dlmenslons/Materlals
Length (inches)
Width (inches)
Height (inches)
Dry Weight (Ibs.)
Hull Design
Hull Material
.
.
.
.
.
.
.
Top Deck Material
Side Rail Material
Front Bumper Material
Base Color
Accent Colors
.
.
.
.
.
Capacities
Rider Capacity
Fuel Reserve (U.S. gallons)
.
.
.
.
5
Engine
be
Carburetion
EC65PW02
Liquid, open system
Electrical
da
Carburetion Intake
Carburetors
.
.
.
.
.
.
.
.
.
er
Engine Model No. .
Engine Cooling
Engine Cylinders
Engine Displacement
Bore & Stroke
Compression Ratio (Full Stroke)
Timing Degrees BTDC
Horsepower
Lubrication
Jet Pump Type
.
Impeller Rotation
Impeller Type
.
.
Counter Clockwise
Progressive pitch. Stainless
rt
Propulsion
OptlonslAccessories
RPM Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Low Oil Monitoring . . . . . . . . . . . . . . . . . . . . . . .
Overheat Warning . ... . . . . . . . . . . . . . . . . . . .
......
.
Bilge Pump Type. . . .. . .
Speedo (Analog)
Fuel Gauge (Analog) . . . . . . . . . . . . . . . . . . . . .
Multi-Function Display
Standard
Buzzer
Buzzer
Siphon 2 GPM
Option
Standard
N/A
"Multi-Function Display includes: Speedometer, Peak Speed, Peak RPM, Tachometer, Clock, Hour Meter, Oil Level , Trip Meter, Low Oil Warning, Fuel Level, Volts , Low Fuel Warning, Hot Engine Warning
1.9
4/96
GENERAL INFORMATION
Polaris reserves the rtght to chenge specifications at
any time without Incurring obligations.
1995 SL65Q
1995 SL65Q STO
1995 SL75Q
.
B954058 (1954058)
B954358 (1954358)
B954070 (1954070)
Length (inches)
Width (inches)
Height (inches)
Dry Weight (Ibs.)
Hull Design
Hull Material
.
.
.
.
.
.
.
105.5"
45 "
37 .5"
9
495
Modified V
(SMC)
105.5"
45 "
37.5 '
9
495
Modified V
(SMC)
105.5"
45"
37.5"
9
499
Modified V
(SMC)
Top Deck Material
Side Rail Material
Base Color
.
.
.
.
SMC
PVC
TPO
White
SMC
PVC
TPO
White (Bottom Hull - Easter
Purple)
SMC
PVC
TPO
White
Accent Colors
.
Purple Velvet / Rubine Red
.
.
.
.
2 person/400 Ibs.
1.03
9.8
2.5
3.5
2 person/400 Ibs .
1.03
9.8
2.5
3.5
2 person/400 Ibs.
1.03
9.8
2.5
3.5
EC65PWE03
Liquid, open system
3
647cc
65mm x65mm
10.7:1
18° at 3000 rpm
68 HP @ 6500 rpm
Oil Injected
EC75PWEOa
Liquid, open system
3
744cc
69 .72mm x Ei5mm
10.5:1
24 ° at 3000 rpm
80 HP @ 6000 rpm
Oil Injected
Model Number
Capacities
Rider Capacity
Fuel Reserve (U .S. gallons)
be
Engine
EC65PWE03
Liquid, open system
3
647cc
65mmx 65mm
10.7:1
18° at 3000 rpm
68 HP @ 6500 rpm
Oil Injected
.
.
Reed Valve
Reed Valve
Reed Valve
3-38mm, 34rnm venturi
Ignition System
.
Starting System
Alternator Output
.
.
Electric Starter
10 Amps /120 watt at 4500
RPM
NGK BPR 7ES
.028 "
Electric Starter
10 Amps / 120 watt at 4500
RPM
NGK BPR 7ES
.028 "
Digital COl , Flywheel
Magneto
Electric Starter
10 Amps /1 20 watt at 4500
RPM
NGK BPR 7ES
.028"
Counter Clockwise
Counter Clockwise
Progressive pitch,
Aluminum, 4 blade PN
5131188
Counter Clockwise
Progressive pitch,
Stainless steel, 4 blade PN
5131079
Standard
MFD Warning Light!
Display
MFD Warning Light /
Display
Standard
Standard
Carburetlon
.
da
Carburetion Intake
Carburetors
.
er
.
.
.
.
.
.
.
.
.
Engine Model No.
Engine Cooling
Engine Cylinders
Engine Displacement
Bore & Stroke
Timing Degrees BTDC
Horsepower
Lubrication
Electrical
.
.
.
rt
Spark Plug Type
Propulsion
Jet Pump Type
.
Impeller Rotation
Impeller Type
.
.
Options/Accessories
RPM Limiter
Low Oil Moritoring
.
.
Standard
Hitone
Standard
Hitone
Overheat Warning
.
Hitone
Hitone
Quick Trim (Power) with Gauge
'Multi-Function Display
Option
N/A
Option
N/A
'Multi-Function Display includes: Speedometer, Peak Speed, Peak RPM, Tachometer, Clock, Hour Meter, Oil Level, Trip Meter, Low Oil Warning, Fuel Level , Volts , Low Fuel Warning, Hot Engine Warning
4/96
1.10
GENERAL INFORMATION
Polaris reserves the right to change specifications at
1995 SLT750
1995 SLX780
Model Number
.
B954170 (1954170)
B954287 (1954287)
Length (inches)
Width (inches)
Height (inches)
Dry Weight (Ibs.)
Hull Design
Hull Material
.
.
.
.
.
.
.
120.3"
47.3"
37.0"
108.5"
47.5"
37.5"
8
9
Top Deck Material
Side Rail Material
Base Color
Accent Colors
Capacities
.
.
.
.
.
530
499
Full V
Modified V
Polyester/glass/foam
(SMC)
composite
Polyester/glass composite
SMC
PVC
PVC
PVC
TPO
Caribbean Blue
White
Purple Velvet / Caribbean Blue Rubine Red / Black
Rider Capacity
Fuel Reserve (U .S. gallons)
Oil Reservoir Capacity (U.S . quarts)
Engine
.
.
.
.
3 person/500 Ibs.
1.2
11
2.5
2 person/400 Ibs.
1.03
9.8
1.5
3.5
5
be
.
.
.
.
.
.
.
.
.
3
3
744cc
69.72mm x 65mm
10.5:1
24 0 at 3000 rpm
Oil Injected
80 HP @ 6000 rpm
779 cc
71 .3mm x 65mm
11.8:1
28 0 at 3000 rpm
Oil Injected
90+ HP @ 6250 rpm
.
.
Reed Valve
Reed Valve
Ignition System
.
Digital COl, Flywheel Magneto
Starting System
Alternator Output
.
.
Spark Plug Type
Propulsion
.
.
Electric Starter
10 Amps / 120 watt at 4500
RPM
NGK BPR 7ES
.028"
Digital COl, Flywheel
Magneto
Electric Starter
10 Amps / 120 watt at 4500
RPM
NGK BPR 8ES
.028"
Jet Pump Type
.
Impeller Rotation
Impeller Type
.
.
EC78PWE02
Liquid, open system
da
Carburetion Intake
Carburetors
Electrical
EC75PWE03
Liquid, open system
er
Engine Model No. .
Engine Cooling
Engine Cylinders
Engine Displacement
Bore & Stroke
Timing Degrees BTDC
Lubrication
Horsepower
Carburetion
rt
Counter Clockwise
steel , 4 blade PN 5131035
Counter Clockwise
Options/Accessories
RPM Limiter
.
Low Oil Monitoring
.
Overheat Warning
.
Low Fuel
.
Bilge Pump Type .. ............. ... . •.
Speedo ............ . ......... • .. . . ..
Fuel Gauge
.
Quick Trim (Power) with Gauge
.
Multi-Function Display
Standard
MFD Warning Light / Display
Siphon 2 GPM
Standard (MFD)
Standard (MFD)
N/A
Standard
Standard
Warning Light
Warning Light / RPM Limiter
Warning Light / RPM Limiter
Siphon 2 GPM
(MFD)
(MFD)
Standard
Standard
*Multi-Function Display includes: Speedometer, Peak Speed, Peak RPM, Tachometer, Clock, Hour Meter, Oil Level, Trip Meter, Low Oil Warning, Fuel Level, Volts, Low Fuel Warning, Hot Engine Warning
1.11
4/96
GENERAL INFORMATION
1996 SL7QQ
1996 SLT7QQ
1996 Hurricane
.
B964066 (1964066)
B964166 (1964166)
B964466 (1964466)
.
.
.
.
.
.
.
.
.
105.5"
45"
37.5"
485
2 person/400 Ibs.
9.8 U.S. Gal (37.1L)
15 minutes
3.5 (3.31L)
(SMC)
120.3"
47.3"
37 "
502
3 person/500 Ibs .
11 U.S. Gal (41.6L)
15 minutes
5 (4.73L)
Polyester/Glass/Foam
Composite
104.8"
37.5"
40.8 "
480
2 person/350 Ibs.
8.6 U.S. Gal (32.6L)
15 minutes
4 (3.78L)
(SMC)
61 miles (99km)
PVC
TPO
68 miles (11 Okm)
PVC
PVC
53 miles (85km)
PVC
TPO
WC70DCSP01/02
700cc
Polaris 2-Stroke (2)
81mmx68mm
11.0:1
80 HP@ 6250 RPM
Water cooled
140· F (60· C)
Buzzer (On @ 160· F)
Case Reed
Oil Injected
Polaris TC-W3
6700 RPM ± 50
WC70DCSP01 /02
700cc
81mm x 68mm
11 .0:1
80 HP@6250 RPM
Water cooled
140· F (60· C)
Case Reed
Oil Injected
Polaris TC-W3
6700 RPM ± 50
WC70DCSP02
700cc
81mm x 68mm
11.5:1
90 HP @ 6700 RPM
Water cooled
140· F (60· C)
Light (MFD)(On@160·F)
Case Reed
Oil Injected
Polaris TC-W3
6700 RPM ± 50
Polaris reservea the right to change apeclflcatlons at
Model Number
Dimensions/Materials/Capacities
Length (inches)
Width (inches)
Height (inches)
Dry Weight (Ibs.)
I~ider Capacity
f~ated Fuel Capacity including reserve
Fuel Reserve
Oil Reservoir Capacity (U.S. quarts)
Hull Material
Full Throttle Cruising Range (Approx)
Side Rail Material
I::nglne/Coollng
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Propulsion
,Jet Pump Type . . . . . . . . . . . . . . . . . . . . . . . .
Impeller Rotation (viewed from rear)
Coupling Type
Bilge Pump Type
Minimum Water Level For Jet Pump. . . . . .
Pivoting Angle
Impeller Type
Impeller Diameter. .. . .... . . . . .... .. .. .
Reverse System
2-38mm, CDK II
Regular Unleaded Gasoline
(87 Octane or 89 if
oxygenated)
1250±50
2-38mm, CDK II
(87 Octane or 89 if
oxygenated)
1350±50
5A /60W at 4500 RPM
Digital CDI
NGK BPR7ES
.028 "
18· at 3000 RPM
12V 19A YB16CL-B
Electric
15A resettable circuit
breaker
5A 1 60W at 4500 RPM
Digital CDI
NGK BPR7ES
.028 "
18· at 3000 RPM
12V 19A YB16CL-B
Electric
breaker
5A 1 60W at 4500 RPM
Digital CDI
NGK BPR7ES
.028 "
20· at 3000 RPM
12V 19A YB16CL-B
Electric
breaker
Single Stage Ax ial Flow
Counterclockwise
Rubber
Electric and Siphon
2 Feet (60cm)
30·
Progressive Pitch Stainless
4 Blade
5.83" (14.8cm)
Option
Counterclockwise
Rubber
Electric and Siphon
2 Feet (60cm)
30·
4 Blade
5.83" (14.8cm)
Standard
Counterclockwise
Rubber
Electric and Siphon
2 Feet (60cm)
30·
3 Blade
5.83" (14.8cm)
N/A
rt
.
.
.
.
.
.
.
.
2-38mm, CDK II
(87 Octane or 89 if
oxygenated)
1250±50
da
Idle Speed (In Water)
1:lectrlcal
Magneto Generator Output
Ignition System
Spark Plug Type
:Spark Plug Gap (inches)
Timing Degrees BTDC
13attery
Starting System
I=use
er
be
Engine Model No. .
Engine Displacement
Engine Type (# Of Cylinders)
Bore & Stroke
Gompression Ratio (Full Stroke)
Horsepower
Gooling System
Thermostat Open
Overheat/Low Oil Warning
Induction Type
Lubrication
Oil Type
I~PM Limiter Operation
Garburetlon
Carburetors (Keihin)
Fuel Type
"Multi-Function Display includes: Speedometer, Peak Speed, Peak RPM, Tachometer, Clock, Hour Meter, Oil Level , Trip Metl3r, Low Oil Warning, Fuel Level, Volts, Low Fuel Warning , Engine Overheat Warning
4/97
1.12
J
GENERAL INFORMATION
Polaris ressrves the right to change specifications at
1996 SL780
1996 SLX780
1996 SLT780
Model Number
Length (inches)
Width (inches)
Height (inches)
Dry Weight (Ibs.)
Rider Capacity
Fuel Reserve
.
B964087 (1964087)
B964287 (1964287)
B964588 (1964588)
.
.
.
.
.
.
.
105.5"
45 "
39.5"
499
2 person/400 Ibs.
9.8
Rev limit/Reserve @4200
RPM
108.5"
47.5 "
39.5 "
499
2 person/400 Ibs.
9.8
RPM
120.3"
49.3 "
39 "
595
3 person/500 Ibs.
14.5
RPM
Hull Material
.
.
3.5
(SMC)
50 miles (80.45 km)
PVC
TPO
3.5
(SMC)
50 miles (80,45 km)
PVC
TPO
5.5
(SMC)
50 miles (80,45 km)
PVC
TPO
.
.
.
.
.
.
.
.
.
.
.
.
.
EC78PWE02 or 03
779cc
Fuji 2-Stroke (3)
71.3mm x 65mm
11.85:1
90+ HP@ 6250 RPM
Water cooled
140° F (60° C)
Light (On @ 180°F)
Case Reed
Oil Injected
Polaris TC-W3
6700 RPM ±70
EC78PWE04
779cc
Fuji 2-Stroke (3)
71 .3mm x 65mm
11.85:1
90+ HP@ 6250 RPM
Water cooled
140· F (60· C)
Light (On @ 180°F)
Case Reed
Oil Injected
Polaris TC-W3
6700 RPM ±70
EC78PWE02,03,or05
779cc
Fuji 2-Stroke (3)
7 1.3mm x 65mm
11.85:1
90+ HP @ 6250 RPM
Water cooled
140° F (60° C)
Light (MFD) (On 180°F)
Case Reed
O il Injected
Polaris TC-W3
6700 RPM ± 70
.
.
(87 Octane or 89 if
oxygenated)
Electrical
.
1250±50
(87 Octane or 89 if
oxygenated)
1250±50
(87 Octane or 89 if
oxygenated)
1250±50
.
Ignition System
Spark Plug Type
Timing Degrees BTDC
Battery
Starting System
Fuse
.
.
.
.
.
.
.
10 Amps 1 120 watt at 4500
RPM
Digital Ignition
NGK BPR8ES
.028"
28° at 3000 rpm (03=24°)
12V 19A YB16CL-B
Electric
breaker
10 Amps 1 120 watt at 4500
RPM
Digital Ignition
NGK BPR8ES
.028"
28° at 3000 rpm
12V 19A YB16CL-B
Electric
breaker
10 Amps 1 120 watt at 4500
RPM
Digital Ignition
NGK BPR8ES
.028"
28° at 3000 rpm (03/05=24°)
12V 19A YB16CL-B
Electric
breaker
Propulsion
Jet Pump Type
Impeller Rotation
Coupling Type
Bilge Pump Type
Minimum Water Level For Jet Pump
Pivoting Angle
Impeller Type
.
.
.
.
.
.
.
Counterclockwise
Rubber
Electric and Siphon
2 Feet (60cm)
30°
4 Blade
5.83" (14.8cm)
Option
Counterclockwise
Rubber
Electric and Siphon
2 Feet (60cm)
30°
3 Blade
5.83" (1 4.8cm)
Option
Counterclockwise
Rubber
Electric and Siphon
2 Feet (60cm)
30°
3 Blade
5.83" (14.8cm)
Standard
t
Impeller Diameter . .... ................
Reverse System
r
da
er
be
Side Rail Material
Engine/Cooling
Engine Model
Engine Displacement
Bore & Stroke
Horsepower
Cooling System
Thermostat Open
Induction Type
Lubrication
Oil Type
RPM Limiter Operation
Carburetlon
Carburetors (Mikuni)
Fuel Type
- Multi-Function Display includes: Speedometer, Peak Speed, Peak RPM , Tachometer, Clock, Hour Meter, Oil Level, Trip Meter, Low Oil Warning, Fuel Level, Volts, Low Fuel Warning , Engine Overheat Warning
1.13
4/97
GENERAL INFORMATION
1996 SL900
1996 SLTX
Model Number
,
Length (inches)
,
Width (inches)
Height (inches)
Dry Weight (Ibs .)
Rider Capa:::ity
Rated Fuel Capacity induding reserve
Fuel Reserve
.
896429 1 (1964291)
B964590 (1964590)
.
.
.
.
.
.
.
120.3 "
49.3 "
39 "
615
3 person/500 Ibs.
14.5
TBA
Hull Material
.
.
108.5 "
47.5"
39.5'
520
2 person/400 Ibs.
9.8
RPM
3.5
(SMC)
50 miles (80.45 km)
PVC
TPO
5. 5
(SMC)
50 miles (80.45 km)
PVC
TPO
WC90TCSPOl
889cc
Polaris 2 Stroke (3)
74.5mm x 68mm
11.01 :1
100+ HP @ 6250 RPM
Water cooled
140 0 F (60 0 C)
Light On @ 160 0 F (71 0 C)
Case Reed
Oi/lnjected
Polaris TC-W3
6700 RPM ± 70
WC105TCSPOl
1050cc
81mm x 68mm
12:1
115+
Water cooled
140 0 F (60 0 C)
Light On @ 160 0 F (71 0 C)
Case Reed
Oi/lnjected
Polaris TC-W3
6700 RPM ± 70
3-38mm, CDK "
(87 Octane or 89 if
oxygenated)
1250±50
3-38mm, CDK II
(87 Octane or 89 if
oxygenated)
1250±50
5A / 60W at 4500 RPM
Digital Ignition
NGK BPR8ES
.028 "
18°@3000
12V 19A YB16CL-B
Electric
15A resettable circuit breaker
5A / 60W at 4500 RPM
Digital Ignition
NGK BPR8ES
.028 "
18°@3000
12V 19A YB16CL-B
Electric
15A resettaole circuit breaker
Impeller Diameter. . . .. . . ...... . .. . . ...
Reverse System
rt
.
Electrical
.
Ignition System
,
Spark Plug Type
.
.
Timing Degrees BTDC
.
'
'
'
Battery
Starting System
, .
Fuse
,
,
,.
Propulsion
Jet Pump Type .. , .... . .... .•. ...... .. '
Impeller Rotation .. . . • ..... .. . . ... , . .
Coupling type
'
.
Bilge Pump Type
.
.
Pivoting Angle
.
.
Impeller Type
,
da
er
be
Full Throttle Cruising Range (Approx) ., . .
Side Rail Material
.
.
Engine/Cooling
Engine Model No. . ,
,. '
'
.
Engine Displacement
,
, .
....,
Engine Type (# Of Cylinders i .
Bore & Stroke . . . . . . .
, . . , , .. , . .
Compression Ratio (Full Stroke) . ... .
Horsepower
, . . .. .'. . . ", .. , . .
Cooling System
' . . ,. , .. , .
.
Thermostat Open . . . . . . . . ,
Overheat Warning
.
Induction Type
'
.
Lubrication
Oil Type. . . . . . . . . . . . . .
,,
.
RPM Limiter Operation . , ..
Carburetlon
' ,
.
FuelType .. . , ... ,
.
Counterclockwise
Rubber
Electric and Siphon
2 Feet (60cm)
Counterclockwise
Rubber
Electric and Siphon
2 Feet (60cm)
30 0
30 0
3 Blade
5.83" (14 .8cm)
Option
3 Blade
5.83' (lJ .8cm)
Standard
' Multi-Function Display includes: Speedometer, Peak Speed, Peak RPM , Tachometer, Clock , H o ur Meter, Oi/ Level , Trip Meter, Low Oil Warning, Fuel Level . Volts, Low Fuel Warning, Engine Overheat Warning
-----------------------4/97
1.14
-_ ..._
._ - - - -,
GENERAL INFORMATION
1997 SL7QQ
1997 SL7QQ Deluxe
1997 SLT7QQ
Model Number
Length (inches)
Width (inches)
Height (inches)
Dry Weight (Ibs.)
Rider Capacity
Fuel Reserve
Oil Reservoir Capacity - U.S. quarts
Hull Material
.
B974071
B974072
B974572
.
.
.
.
.
.
.
.
.
105.5" (268 cm)
45" (114.3cm)
37.5" (95.25 cm)
480 (218.4 kg)
2 person/400 Ibs.
12.5 U.S. Gal (47.3L)
15 minutes
3.5 (3.31L)
(SMC)
61 miles (99 km)
PVC
TPO
105.5" (268 cm)
45" (114 .3 cm)
37.5 " (95.25 cm)
485 (220.68 kg)
2 person/400 Ibs.
12.5 U.S. Gal (47.3L)
15 minutes
3.5 (3 .31L)
(SMC)
61 miles (99 km)
PVC
TPO
120.3" (306 cm)
49.3" (123.22cm)
39 " (99 .06 cm)
595 (269.89)
3 person/500 Ibs.
15 U.S. Gal (56.8L)
15 minutes
5.5 (5.2L)
(SMC)
68 miles (110 km)
PVC
TPO
.
.
.
.
.
.
.
.
.
.
.
.
.
WC70SCSP01
700cc
81mmx68mm
11.5:1
82.5 HP @ 6200 RPM
Water cooled
140· F (60· C)
Case Reed
Oil Injected
Polaris TC-W3
6700 RPM ± 100
WC70DCSP05
700cc
81mm x 68mm
10.4: 1
85 HP @ 6350 RPM
Water cooled
140· F (60 0 C)
Buzzer (On @ 1600 F)
Case Reed
Oil Injected
Polaris TC-W3
6700 RPM ± 100
WC70DCSP05
700cc
81mm x 68mm
10.4:1
85 HP @ 6350 RPM
Water cooled
140· F (60· C)
Buzzer (On @ 160 0 F)
Case Reed
Oil Injected
Polaris TC-W3
6700 RPM ± 100
Side Rail Material
Engine/Cooling
.
.
.
1-40mm, CDK II
(87 Octane or 89 if
oxygenated)
1250±50
5A / 60W at 4500 RPM
Digital COl
NGK BPR8ES
.028"
18 0 at 3000 RPM
12V 19A YB16CL-B
Electric
breaker
Propulsion
Jet Pump Type
Impeller Rotation (viewed from rear)
Coupling Type
Bilge Pump Type
Pivoting Angle
Impeller Type
.
.
.
.
.
.
.
Counterclockwise
Rubber
Electric
2 Feet (60cm)
3D·
3 Blade 12-17 Swirl
5.83" (14.8cm)
Option
Impeller Diameter ... . . ..... . . . .. . . ....
Reverse System
2-38mm, CDK II
(87 Octane or 89 if
oxygenated)
1250±50
5A / 60W at 4500 RPM
Digital CDI
NGK BPR7ES
.028 "
18 0 at 3000 RPM
12V 19A YB16CL-B
Electric
breaker
5A / 60W at 4500 RPM
Digital COl
NGK BPR8ES
.028"
18 0 at 3000 RPM
12V 19A YB16CL-B
Electric
breaker
Counterclockwise
Rubber
Electric
2 Feet (60cm)
30·
3 Blade 12-17 Swirl
5.83" (14.8cm)
Option
Counterclockwise
Rubber
Electric
2 Feet (60cm)
30·
3 Blade 12-17 Swirl
5.83" (14.8cm)
Option
rt
Starting System
Fuse
.
.
.
.
.
.
.
.
~ttery
2-38mm, CDK II
(87 Octane or 89 if
oxygenated)
1250±50
da
Electrical
Ignition System
Spark Plug Type
Timing Degrees BTDC
er
be
Engine Model No. .
Engine Displacement
Bore & Stroke
Horsepower
Cooling System
Thermostat Open
Induction Type
Lubrication
Oil Type
Carburetlon
Fuel Type
' Multi-Function Display includes: Speedometer, Peak Speed, Peak RPM , Tachometer, Clock, Hour Meter, Oil Level , Trip Meter, Low Oil Warning , Fuel Level , Volts, Low Fuel Warning , Hot Engine Warning
1.14a
4/97
GENERAL INFORMATION
Polaris reserves tha right to change speclllcatJons at
Model Number
Length (inches)
Width (inches)
Height (inches)
Dry Weight (Ibs.)
Rider Capacity
Fuel Reserve
Hull Material
1997 SL78Q
1997 SLT78Q
.
B974473
B974088
B974588
.
.
.
.
.
.
.
.
.
104.8" (266.2 em)
37.5 " (95.25 em)
40.8" (103.6 em)
480 (218.4 kg)
2 person/350 Ibs.
8.6 U.S. Gal (32.6L)
15 minutes
3.5 (3 .31L)
(SMC)
53 miles (85 km)
PVC
TPO
105.5" (268 em)
45" (114 .3 em)
39.5 " (100.33 em)
499 (226.3 kg)
2 person/400 Ibs. (182 kg)
12.5 (47.31)
15 rrinutes
3.5 (3.31L)
(SMC)
65 miles (104.6 km)
PVC
TPO
120.3" (305.56 em)
49.3" (125.22 em)
39 " (99.06 em)
605 (274.42 kg)
15 (56.781)
15 minutes
5.5 (5.21)
(SMC)
80 miles (128.75 km)
PVC
TPO
.
.
.
.
.
.
.
.
.
.
.
.
.
WC70DCSP04
700cc
81mm x 68mm
11 .5:1
90 HP @ 6700 RPM
Water cooled
140· F (60· C)
Light (MFD)(On@160·F)
Case Reed
Oil Injected
Polaris TC-W3
7200 RPM ± 100
EC78PWE03
779cc
Fuji 2-Stroke (3)
71 .3mm x 65mm
11 .85 :1
93 HP @ 6250 RPM
Water cooled
140· F (60· C)
4200 Rev Limit @ 180·F
Case Reed
Oil Injected
Polaris TC-W3
6700 RPM ± 70
EC78PWE03
779cc
Fuji 2-Stroke (3)
71 .3mm x 65mm
11 .85:1
93 HP @ 6350 RPM
Water cooled
140· F (60· C)
4200 Rev Limit @ 180· F
Case Reed
Oil Injected
Polaris TC-W3
6700 RPM ± 70
er
be
Side Rail Material
Engine/Cooling
Engine Model
Engine Displacement
Bore & Stroke
Horsepower
Cooling System
Thermostat Open
Induction Type
Lubrication
Oil Type
Carburetlon
Carburetors (Mikuni)
Fuel Type
1997 Hurricane
.
5A / 60W at 4500 RPM
Ignition System
Spark Plug Type
Timing Degrees BTDC
Battery
Starting System
Fuse
.
.
.
.
.
.
.
Digital COl
NGK BPR8ES
.028"
20· at 3000 RPM
12V 19A YB16CL-B
Electric
breaker
Propulsion
Jet Pump Type
Impeller Rotation
Coupling Type
Bilge Pump Type
Pivoting Angle
Impeller Type
.
.
.
.
.
.
.
3-38mm/34mm venturi Mikuni
(87 Octane or 89 if
oxygenated)
1250±50
da
.
2-38mm, CDK II
(87 Octane or 89 if
oxygenated)
1350±50
Electrical
.
.
10 Amps / 120 watt at 4500
RPM
Digital Ignition
NGK BPR8ES
.028"
24 · @ 3000 rpm
12V 19A YB1 6CL-B
Electric
breaker
rt
10 Amps / 120 watt at 4500
RPM
Digital Ignition
NGK BPR8ES
.028 "
24· at 3000 rpm
12V 19A YB16CL-B
Electric
breaker
3-38mm/34mm venturi Mikuni
(87 Octane or 89 if
oxygenated)
1250±50
Counterclockwise
Counterclockwise
Counterclockwise
Rubber
Rubber
Rubber
Electric
Electric
Electric
2 Feet (60cm)
2 Feet (60cm)
2 Feet (60cm)
30·
30·
30·
3 Blade
4 Blade
3 Blade
Impeller Diameter
5.83" (14.8cm)
5.83" (14.8cm)
5.83" (14.8cm)
Reverse System
N/A
Option
Standard
'Multi-Function Display includes : Speedometer, Peak Speed, Peak RPM , Tachometer, Clock, Hour Meter, Oil Level , Trip Met'3r, Low Oil Warning, Fuel Level , Volts, Low Fuel Warning , Hot Engine Warn ing
4/97
1.14b
GENERAL INFORMATION
Polaris raservea the rig ht to chenge apeclflcatlona at
1997 SL900
1997 SL 1050
1997 SLTX
Model Number
Length (inches)
Width (inches)
Height (inches)
Dry Weight(lbs.)
Rider Capacity
Fuel Reserve
Hull Material
.
B974091
B974090
B974590
.
.
.
.
.
.
.
.
.
.
.
.
108.5" (276 cm)
47 .5" (120.65)
39.5" (100.33 cm)
520 (236.08 kg)
12.5 (47.31)
N/A
3.5 (3.311)
(SMC)
40 miles (64 .37 km)
PVC
TPO
120.3" (305.56 cm)
49.3" (125.22 cm)
39" (99.06 cm)
615 (278.96 kg)
3 person/500 Ibs.
15 (56.781)
N/A
5.5 (5.201)
(SMC)
Side Rail Material
Engine/Cooling
Engine Model No. .
Engine Displacement
Bore & Stroke
Horsepower
Cooling System
Thermostat Open
Overheat Warning
Induction Type
Lubrication
Oil Type
Carburetlon
Fuel Type
108.5" (276 cm)
47.5" (120.65)
39.5" (100.33 cm)
520 (236.08 kg)
12.5 (47.31)
N/A
3.5 (3.31 L)
(SMC)
50 miles (80.45 km)
PVC
TPO
WC90TCSP01
900cc
74.5mm x 68mm
12:1
107 HP @ 6350 RPM
Water cooled
140° F (60° C)
Light On @ 160° F (71 ° C)
Case Reed
Oil Injected
Polaris TC-W3
6800 RPM ± 100
WC105TCSP02
1050cc
81mm x 68mm
12:1
119 HP@6500
Water cooled
140° F (60° C)
4500 Rev Limit @ 160°F (71°C)
Case Reed
Oil Injected
Polaris TC-W3
6800 RPM ± 100
WC105TCSP03
1050cc
81mmx 68mm
12:1
119 @ 6500
Water cooled
140· F (60· C)
4500 Rev Limit @ 160°F (71 0C)
Case Reed
Oil Injected
Polaris TC-W3
6800 RPM ± 100
be
.
.
.
.
.
.
.
.
.
.
3-38mm, CDK II
(87 Octane or 89 if
oxygenated)
1200-1300
.
.
.
.
.
.
.
.
5A /60W at 4500 RPM
Digital I Sequential Ignition
NGK BPR8ES
.028"
18°@3000
12V 19A YB16CL-B
Electric
.
.
.
.
.
.
.
Single Stage Axial Flow-4" Ext
Counterclockwise
Rubber
Electric
2 Feet (60cm)
30°
3 Blade
5.83" (14.8cm)
Option
.
.
3-40mm, CDK II
(87 Octane or 89 if
oxygenated)
1200-1300
da
3-38mm, CDK II
(87 Octane or 89 if
oxygenated)
1250±50
5A /60W at 4500 RPM
Digital/ Sequential Ignition
NGK BPR8ES
.028"
18°@3000
12V 19A YB16CL-B
Electric
5A 160W at 4500 RPM
NGK BPR8ES
.028"
18°@3000
12V 19A YB16CL-B
Electric
Counterclockwise
Rubber
Electric
2 Feet (60cm)
30°
3 Blade
5.83" (14.8cm)
Option
Counterclockwise
Rubber
Electric
2 Feet (60cm)
30°
3 Blade
5.83" (14.8cm)
Standard
rt
Impeller Diameter
Reverse System
er
Electrical
Ignition System
Spark Plug Type
Timing Degrees BTDC
Battery
Starting System
Fuse
Propulsion
Jet Pump Type
Impeller Rotation
Coupling type
Bilge Pump Type
Pivoting Angle
Impeller Type
.
.
.
55 miles (88.5 km)
PVC
TPO
'Multi-Function Display includes: Speedometer, Peak Speed, Peak RPM, Tachometer, Clock, Hour Meter, Oil Level, Trip Meter, Low Oil Warning, Fuel Level, Volts, Low Fuel Warning, Hot Engine Warning
1.14c
4/97
GENERAL INFORMATION
Polaris reserves the right to change specifications at any time without incurring obligations.
1998 SLH
Model Number
.
Length (inches) ...
Width (inches) ..
Height (inches) ... ,
Dry Weight (Ibs.)
Rider Capacity .. . .
.
,
Rated Fuel Capacity including reserve ..
Fuel Reserve ..
. , ... , .....
Oil Reservoir Capacity - U.S. quarts ..
Hull Material
.
,
.
B984673
1998 SLTH
B984573
108.5" (276 cm)
47 .5" (120.7 cm)
39.5 ,. (100 .3 cm)
460 (209 kg)
2 person/400 Ibs . (182 kg )
t2 .5 U.S. Gal (47.3L)
N/A
5 (4 73L)
(SMC)
61 miles (85 km)
PVC
TPO
120.3" (305 .56 cm)
49 .3" (123.22 cm)
39 " (99.06 cm)
595 (270 kg)
3 person/SOC Ibs. (227 kg)
15 U.S . Gal (56.8L)
N/A
5.5 (5.203L)
(SMC)
68 miles (104.6 km)
PVC
TPO
WC 7 0DCSP-06A2
700cr;
81mm x 68mm
11 .5: I
95 HP @ 6700 RPM
Water cooled
140' F (60° C)
Light (MFD)(On @160°F)
Case Reed
Oil Injected
Polaris TC-W3
7200 RPM ± 100
WC70DCSP- 06A 1
700cc
81mm x 68mm
11.5:1
95 HP @ 6700 RPM
Water cooled
140° F (60° C)
Light (MFD)(On @160°F)
Case Reed
Oil Injected
Polaris TC-W3
7200 RPM ± 100
.
'
.,
.
.
.
2-38mm, CDK II
(87 Octane or 89 if
oxygenated)
1350±50
da
2-38mm , CD K II
(87 Octane or 89 if
oxygenated )
1350±50
5A / 60W at 4500 RPM
Digital COl
NGK BPR8ES
.028 "
18°±2 at 3000 RPM
13°±2 at 6250 RPM
12V 19A YB16CL-B
Electric
breaker
SA / 60W at 4500 RPM
Digital CDI
NGK BPR8ES
028 "
18' ±2 at 3000 RPM
13°±2 at 6250 RPM
12V 19A YB 16CL-B
Electric
15A resettab le circuit
breaker
Counterclockwise
Rubber
Electri c
2 Feet (60cml
30'
3 Blade
5.83" (14 ,8cm)
N/A
Counterclockwise
Rubber
Electric
2 Feet (60cm)
30°
Progressive I"itch Stainless
3 Blade
5.83" (14.8crn)
Standard
rt
Battery
.
Starting System
Fuse . ..
Propulsion
Jet Pump Type . .
Impeller Rotation ...
Coupling Type
Bilge Pump Type
. , , . , .. , . ,
Minimum Water Level For Jet Pump .
Pivoting Angle
,.,
Impeller Type ..
Impeller Diameter
Reverse System ..
,
.
er
Electrical
Ignition System
.
Spark Plug Type
.
Timing Degrees BTDC
.
.
.
.
be
Side Rail Material . , .. , . , ,
Front Bumper Material ..
Engine/Cooling
Engine Model
Engine Displacement . ,
.
Engine Type (# Of Cylinders) . ,
Bore & Stroke . . . ..
Compression Ratio (Full Stroke ) . .
Horsepower
..,,..... .
Cooling System
.
Thermostat Open.
Induction Type .
.
Lubrication . .
.
Oil Type
,
,.. .
Carburetion
Carburetors
.
FuelType
,
.
...'
.
.
,.,
.
.
.
.
.,..................... . ......
............
'Multi-Function Display includes : Speedometer, Peak Speed, Peak RPM , Tachometer, Clock, Hour Meter, Oil Level , Trip
Meter, Low Oil Warning , Fuel Level . Volts, Low Fuel Warning, Hot Engine Warning
5/98
1.14d
GENERAL INFORMATION
Polaris reserves the right to change specifications at any time without incurring obligations.
1998 SLXH
1998 SLTX
Model Number .. . .
.
.
length (inches)
Width (inches)
.
Height (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dry Weight (Ibs .)
Rider Capacity
.
.
Fuel Reserve .. .
Hull Material
.........
.
.
B984690
B984590
108.5" (276 cm)
47.5 " (120.65)
39.5 " (100.33 cm)
530 (241 kg)
12.5 U.S. Gal (47 .3l)
N/A
5 (4.731)
(SMC)
40 miles (64.37 km)
PVC
TPO
120.3" (305 .56 cm)
49.3" (125 .22 cm)
39 " (99.06 cm)
615 (279 kg)
15 (56.8l)
N/A
5.5 (5 .201)
(SMC)
55 miles (88 .5 km)
PVC
TPO
WC105TCSP-05
1050cc
81mmx 68mm
10.4:1
120 HP @ 6500
Water cooled
140° F (60° C)
4500 Rev limit @ 160°F (71 °C)
Case Reed
Oil Injected
Polaris TC-W3
6800 RPM ± 100
WC105TCSP-04
1050cc
81mm x 68mm
10.4:1
120 @ 6500
Water cooled
140° F (60° C)
4500 Rev Limit @ 160°F (71 °C)
Case Reed
Oil Injected
Polaris TC-W3
6800 RPM ± 100
.
.
.
.
.
.
.
.
.
.
be
Side Rail Material.
Engine/Cooling
Engine Model No. .
Engine Displacement
.
Bore & Stroke . . . . . . . . .
Compression Ratio (Full Stroke) . . . . . . . . . . . . .
Horsepower
.
Cooling System
..........
Thermostat Open . . . . . . . . . . .
Overheat Warning
.
Induction Type
lubncation
.
.
.
.
Oil Type.. ..
.
Carburetion
.
.
.
Fuel Type ..
.
.
.
.
.
.
.
.
3-40mm, CDK II
RegUlar Unleaded Gasoline
(87 Octane or 89 if
oxygenated)
1350150
da
.
.
.
3-40mm, CDK II
(87 Octane or 89 if
oxygenated)
1350±50
5A / 60W at 4500 RPM
NGK BPR8ES
.028 "
18°+0,-2 @3000
11 °+0,-2 @6250
12V 19A YB16Cl-B
Electric
5A /60W at 4500 RPM
NGK BPR8ES
.028"
18°+0,-2 @3000
11 °+0,-2 @6250
12V 19A YB16Cl-B
Electric
Counterclockwise
Rubber
Electric
2 Feet (60cm)
30°
3 Blade
5.83" (14.8cm)
N/A
Counterclockwise
Rubber
Electric
2 Feet (60cm)
30°
3 Blade
5.83" (14.8cm)
Standard
rt
Battery
.
Starting System
Fuse.
Propulsion
Jet Pump Type.
Impeller Rotation
Coupling type . . . ..
Bilge Pump Type
.
Minimum Water level For Jet Pump ..
Pivoting Angle
Impeller Type .
.
Impeller Diameter
Reverse System
.
er
Electrical
Ignition System
Spark Plug Type
Timing Degrees BTDC
.
.
.
.
.
.
.
.
...........
'Multi-Function Display includes: Speedometer, Peak Speed, Peak RPM, Tachometer, Clock, Hour Meter, Oil Level, Trip
Meter, Low Oil Warning, Fuel Level , Volts, Low Fuel Warning, Hot Engine Warning, Compass (SLTX only)
1.14e
5/98
GENERAL INFORMATION
da
er
be
rt
5/98
1.14f
GENERAL INFORMATION
Standard Torque Specifications
The following torque specifications are to be used as a general guideline. Use standard torque values for the
appropriate size fastener when torque values are not specified. Always consult the specific manual section
for torque values of fasteners and use of locking agent.
RECOMMENDED TORQUE SPECIFICATION
STAINLESS STEEL FASTENERS (SAE)
Bolt Size
Threads/Inch
Torque
8
18 & 32
28 in.lbs.
10
24 &32
40 in . lbs.
1/4
20 &28
8 ft . Ibs.
5/16
18 & 24
14 ft. Ibs.
3/8
16
25 ft. Ibs.
3/8
24
28 ft. Ibs.
7/16
14
40 ft. Ibs.
1/2
13
58 ft. Ibs.
1/2
20
70 ft. Ibs.
be
RECOMMENDED TORQUE SPECIFICATION
STAINLESS STEEL FASTENERS (METRIC)
5mm
6mm
8mm
12mm
45-52 in. Ibs.
66-78 in. Ibs.
13-16 ft. Ibs.
26-30 ft. Ibs.
40-44 ft. Ibs.
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•
•
•
Torque
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10mm
er
Bolt Size
To convert in. Ibs. to ft. Ibs. divide by 12
To convert ft. Ibs. to kg-m multiply foot pounds by .138.
To convert kg-m to Nm move the decimal to the right one position.
1.15
4/96
GENERAL INFORMATION
Decimal Equivalents
1/64
.
.
.
.
.
.
1/32
3/64
_
1/16
5/64
3/32
7/64
1/8
9/64
5/32 . _
,. .
3/16
13/64
,
7/32
15/64
11/64
1/4
17/64
9/32 . _
19/64
5/16
21/64
11/32
23/64
3/8
13/32
27/64
29/64
31/64
._
,
7.'16. ,
15/32 .. _
,
_
1/2
33/64
17/32
35/64
9/16
19/32
39/64
5/8
41/64
,
21/32
,
43/64
2
mm
= .0787"
3
mm
= .1181"
4
mm = .1575"
5 rnm = .1969"
6
mm = .2362"
7 mm
8
mm
23/32
47/64
3/4
49/64
25/32
51/64
13/16
53/64
_
,
_
7/8
27/32
55/64
57/64
29/32
59/64
_
15/16
61/64
31/32
_
63/64
1
_
.2756"
=
= .3150"
9 mm = .3543"
10 mrn = .3937"
11
mm = .4331 "
12 mm = .4724"
13
mm
= .5118
14 mm = .5512"
15
mm = .5906"
16 rnm = .6299"
17
mm = .6693"
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11/16
45/64
4/96
mm = .0394"
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37/64
1
er
be
25/64
.
.
.
.
.
.
.
.
..
.
.
.
..
.
.
.
.
.
.
.
.
.
.
.
.
.
..
.
.
.
.
.
..
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
..
.0156
.0312
.0469
.0625
.0781
.0938
.1 094
1250
.1406
.1563
.1719
.1875
.2031
.2188
.2344
.25
.2656
.2813
.2969
.3125
.3281
.3438
.3594
.375
.3906
.4063
.4219
.4375
.4531
.4688
.4844
.5
.5156
.5313
.5469
.5625
.5781
.5938
.6094
.625
.6406
.6563
.6719
.6875
.7031
.7188
.7344
.75
.7656
.7813
.7969
.8125
.8281
.8438
.8594
.875
.8906
.9063
.9219
.9375
.9531
.9688
.9844
1.0
18 mm
= .7087"
mm
= .7£180"
19
20 mm = .7874"
21
mm = .8268"
22 mm = .8661 "
23 mrn = .9055"
24 mrn = .9449 "
25 mrn
1.16
=
.9843
GENERAL INFORMATION
Conversion Table
Multiplied by
Unit of Measure
Converts to
x12
= in.lbs.
in.lbs.
x .0833
= ft. Ibs.
ft. Ibs.
x .1383
= kg-m
in.lbs.
x .0115
= kg-m
kg-m
x 7.233
= ft. Ibs.
kg-m
x 86.796
= in. lbs.
kg-m
x10
= Nm
in.
x 25.4
=mm
mm
x .03937
= in.
in .
x 2.54
=cm
mile (mi.)
x 1.6
=km
km
x .6214
= mile (mi.)
Ounces (oz)
x 28.35
= Grams (g)
Grams (g)
x 0.035
= Ounces (oz)
lb.
x .454
= kg
x 2.2046
= lb.
Cubic inches (cu in)
x 16.387
= Cubic centimeters (cc)
Cubic centimeters (cc)
x 0.061
= Cubic inches (cu in)
Imperial pints (Imp pt)
x 0.568
= Liters (I)
kg
Liters (I)
Imperial quarts (Imp qt)
Liters (I)
x 1.76
= Imperial pints (Imp pt)
x 1.137
= Liters (I)
x 0.88
= Imperial quarts (Imp qt)
x 1.201
= US quarts (US qt)
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Imperial quarts (Imp qt)
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ft. Ibs.
US quarts (US qt)
x 0.833
= Imperial quarts (Imp qt)
US quarts (US qt)
x 0.946
Liters (I)
x 1.057
US gallons (US gal)
x 3.785
Liters (I)
x 0.264
Pounds - force per square inch (psi)
x 6.895
Kilopascals (kPa)
x 0.145
= Pounds - force per square inch
Kilopascals (kPa)
x 0.01
= Kilograms - force per square cm
Kilograms - force per square em
x 98.1
= Kilopascals (kPa)
= Liters (I)
= US quarts (US qt)
rt
=Liters (I)
= US gallons (US gal)
= Kilopascals (kPa)
(psi)
°C to of: 9 (OC + 40) + 5 - 40 = of
of to °C: 5 (OF + 40) + 9 - 40 = °C
1.17
4/96
GENERAL INFORMATION
Tap Drill Charts
SAE Tap Drill Sizes
Drill Size
Thread Size
Drill Size
#0-80
#1-64
#1-72
#2-56
#2-64
#3-48
#3-56
#4-40
#4-48
#5-40
#5-44
#6-32
#6-40
#8-32
#8-36
#10-24
#10-32
#12-24
#12-28
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
3/64
53
53
51
50
5/64
45
43
42
38
37
36
33
29
29
24
21
17
4.6mm
7
3
1/2-13
1/2-20
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
7/8-14
1-8
1-12
1 1/8-7
1 1/8-12
1 1/4-7
1 1/4-12
1 1/2-6
1 1/2-12
1 3/4-5
1 3/4-12
2-41/2
2-12
21/4-41/2
2 1/2-4
2 3/4-4
3-4
27/64
29/64
31/64
33/64
17/32
37/64
21/32
11/16
49/64
13/16
7/8
59/64
63/64
1 3/64
1 7/64
1 11/64
1 11/32
1 27/64
1 9/16
1 43/64
1 25/32
1 59/64
2 1/32
2 1/4
2 1/2
2 3/4
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Thread Size
F
I
Q
U
25/64
Metric Tap Drill Sizes
Tap Size
4/96
Drill Size
#39
3/32
#30
1/8
#19
#20
#9
16/64
Decimal Equivalent
0.0995
0.0937
0.1285
0.125
0.166
0.161
0.196
0.234
0.277
0.265
0.3125
0.3125
0.3437
0.339
0.375
0.406
0.406
Nearest Fraction
3/32
3/32
1/8
1/8
11/64
5/32
13/64
15/64
9/32
17/64
5/16
5/16
11/32
11/32
3/8
13/32
13/32
rt
3 x .50
3 x .60
4 x .70
4 x .75
5 x .80
5 x .90
6 x 1.00
7 x 1.00
8 x 1.00
8 x 1.25
9 x 1.00
9 x 1.25
10 x 1.25
10 x 1.50
11 x 1.50
12 x 1.50
12 x 1.75
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0
J
17/64
5/16
5/16
11/32
R
3/8
13/32
13/32
1.18
GENERAL INFORMATION
Glossary Of Terms
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ABDC: After bottom dead center.
ATOC: After top dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
BBOC: Before bottom dead center.
BDC: Bottom dead center.
BTOC: Before top dead center.
Bow: The front of a watercraft
C: Celsius
CC: Cubic centimeters.
COl: Capacitor discharge ignition. Ignition system which stores voltage generated by the stator plate exciter coil
in a capacitor or condenser (in COl box). At the proper moment a voltage generated by the stator plate pulser coil
closes an electronic switch (thyristor) in the COl box and allows the voltage in the capacitor to discharge into the
primary windings of the ignition coil.
CI: Cubic inches.
Condenser/Capacitor: A storage reservoir for electricity, used in both E.T. and COl systems.
Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is
supported between centers on V blocks or resting in lower half of crankcase. Measure at various points especially
at the PTa end.
DCV: Direct current voltage.
Detonation: The spontaneous ignition of the unburned fuel/air mixture afternormal ignition spark occurs. Piston
looks "hammered" through, rough appearance around hole. Possible causes: 1) Compression ratio too high for
the fuel octane; 2) low octane fuel; 3) over-advanced ignition timing.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and
out-of-round in the cylinder bore.
End Seals: Rubber seals at each end of the crankshaft.
F: Fahrenheit
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system. There are 28 grams in one ounce.
gal.: Gallon.
Head Volume (Unlnstalled): Cylinder head capacity in cc, head removed from engine with spark plug installed.
High Tension Lead: The heavy insulated wire which carries the high secondary voltage from the coil to the spark
plug.
Holed Piston: Piston in which a hole has formed on the dome. Possible causes: 1) detonation; 2) pre-ignition.
HP: Horsepower.
10: Inside diameter.
Ignition Coil: A type of transformer which increases voltage in the primary windings (approx. 200V) to a higher
voltage in the secondary windings (approx. 14KV - 32KV) through induction. Secondary voltage must be high
enough to ionize the air gap at the spark plug.
Ignition Generating Coil: Exciter coil , primary charge coil. Stator plate coil which generates primary ignition
voltage.
in.: Inch/inches.
rt
kglcm 2 : Kilograms per square centimeter.
Kg-m: Kilogram meters.
Km: Kilometer.
Kilogram meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
1.19
4/96
GENERAL INFORMATION
Glossary Of Terms
I or Itr: Liter. One liter = 1.0567 U.S. quarts.
Ibslin
2 :
Pounds per square inch .
Inch Pound: In. lb. 12 in . Ibs. = 1 ft. lb.
I.eft Side: The left hand side of the vehicle. Referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
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er
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Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the
windings. This is how mechanical energy is converted to electrical energy in the lighting coil, ignition generating
coils and trigger coil.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1mm = .040".
N-m: Newton meters.
00: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
Open Circuit: An electrical circuit which is incomplete. (e.g . poor connections or broken wire preventing the flow
of current) .
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall .
Piston Erosion: Piston dome melts. Usually occurs at the exhaust port area. Possible causes: 1) lean fuel/air
mixture ; 2) improper spark plug heat range.
Pre-Ignition: A problem in combustion where the fuel/air mixture is ignited before normal spark ignition. Piston
looks melted at area of damage. Possible causes: 1) Spark plug heat range incorrect (too hot) 2) spark plug not
properly torqued ; 3) "glowing" piece of head gasket, metal burr or carbon in the combustion cha mber; 4) lean
fuel/air mixture.
Primary Circuit: This circuit is responsible for the voltage build up in the COl capacitor. In a COl system the parts
include the exciter coil, the trigger coil, the wires from stator plate to COl box and to the ignition coil primary
windings.
psi.: Pounds per square inch.
pts: Pint/pints
PTO: Power take off.
qt.: Quart/quarts.
I~PM: Revolutions per minute.
I~esistance: In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy
conversion to heat.
Right Side: The right hand side of the vehicle . Always Referred to based on normal ooerating position of the rider.
RPM: Revolutions per minute.
I~unning Time: Ignition timing at specified RPM.
Secondary Circuit: This circuit consists of the ignition coil secondary windings, high tension wire and ground
through the spark plug air gap.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the
cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston
clearance; 4) stuck piston rings.
Short Circuit: An electrical circuit which is completed before the current reaches the intended component. (e.g.
a bare wire touching a grounded component.
Spark Plug Reach: Length of threaded portion of spark plug. Polaris uses 3/4" (2 em) reach plugs.
Static Timing: Ignition timing when engine is at zero RPM.
Stator Plate: The plate mounted under the flywheel supporting the primary ignition components and lighting coil.
TOC: Top dead center. Piston's most outward travel from crankshaft.
Trigger Coil: Pulser coil. Generates the voltage for triggering (closing) the thyristor and timing the spark in COl
systems. Small coil mounted at the top of the stator plate next to the ignition generating coil.
rt
Voltage Regulator: An electrical device which prevents overcharging of the battery or overloading of electrical
components as engine RPM increases.
4/96
1.20
GENERAL INFORMATION
Special Tools
ELECTRICAL
Fluke 73 Analog/Digital Multitester
Tests all electrical circuits and components.
PN 2870659
Strobe Timing Light
High intensity strobe, works on all types of ignition
systems (self-contained).
PN 2870630
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Digital Tachometer
See page 1.26
ENGINE
Piston Pin Puller
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Removes 18mm piston pins from all Polaris/Fuji PWC
engines.
PN 2870386
Piston Pin Puller Adaptor
(For Use With 2870386)
PN 2871445 (700, 900, 1050) Pol/Domestic Engines
1
-I.'I
..
_
.. - _
.
. ~.~-
-,
-,~
,
t
Piston Support Block
Supports piston and prevents piston skirt damage during
cylinder installation.
PN 2870390
1.21
4/97
GENERAL INFORMATION
Special Tools
ENGINE
Piston Pin C-clip Installation Tool
Used to install C-clip style piston pin retainers to
prevent clip distortion or piston damage. Fits 18mm
C-clips.
PN 2870773
Cylinder Hone (Ammco Model No. 3950)
r:~igid cylinder hone for de-glazing and truing heat
distorted cylinders.
I:>N 2870303
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Replacement Ammco Hone Sets
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Cylinder Hone Fine Stone Set Std. (Ammco No. 3952)
PN 2870305
Cylinder Hone Course Stone Set Std. (Ammco No. 3951)
PN 2870304
Cylinder Hone Course Stone Set O.S. (Ammco No. 3953)
PN 2870306
rt
Cylinder Hone Fine Stone Set O.S. (Ammco No. 3954)
PN 2870307
NOTE: O.S. Stone Sets range from 21/2 " to 3 3/8 "
I
Honing Oil
Improves hone operation and prevents stone loading.
PN 2870588
4/97
1.22
GENERAL INFORMATION
Special Tools
ENGINE
Crankshaft Alignment Kit
Used for checking and straightening crankshafts on all
engines.
PN 2870569
Flywheel Puller
For all 3 bolt pattern flywheels.
Items in square are for watercraft only.
PN 2871043
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Engine Cylinder Compression Gauge
PN 2870852
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Flywheel Holder
PN 8700229
PN 8700229-Adapt Adapter for Fuji PWC Engines
1.23
4/97
GENERAL INFORMATION
Special Tools
PUMP
Pump Alignment Tool
This tool is used to obtain proper alignment between
the engine and the jet pump.
PN 2871343
-
-
Impeller Removal Tool
This tool is used to remove the pump impeller on all
models of watercraft. Can be identified by 3 knurled
sections on the shaft of the tool, and by diameter.
PN 2871036
0 -,-'-'----
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I)rive Coupler Removal Tool
Impeller Removal Tool
has 3 knurled sections
Note: Not For Use On
Bonded Rubber Coupler
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This tool is used to remove the (1-piece) drive shaft
coupler from the end of the crankshaft. Can be
identified by 2 knurled sections on shaft, and by
diameter. This tool is not for use on bonded rubber
couplers.
PN 2871037
21.65mm (.852")
r --
\-\---Bi
;~, ~~.
~,~, } ~~(~
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Engine Coupler
--..~
(.787")
O- ~omm
t
Driveshaft Through Hull Fitting Socket
This tool is used to remove and install the threaded
drive shaft through-hull fitting used on 1995 SL650
:STD and 1995 SLX780 model watercraft.
I?N 2871425
4/97
1.24
GENERAL INFORMATION
Special Tools
GENERAL
Ignition Timing Dial Indicator
0-1 /1 Range
Indicates piston BTDC position for timing all engines.
PN 2870459
Dial Indicator Extension 2870459-6484
Battery Hydrometer
Accurate small battery specific gravity hydrometer.
PN 2870836
1M
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Mity Vac
Pump Kit
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This tool is used for many service functions on Polaris
Personal Watercraft including fuel system pressure and
vacuum testing, and pop-off pressure testing.
PN 2870975
t
Carburetor Synchronizing Manometer
Accurate synchronization of multi carbureted engines
which are equipped with vacuum spigots.
PN 2870672
1.25
4/97
GENERAL INFORMATION
Special Tools
GENERAL
Carburetor Mixture Needle Adjuster
PN 2871080
Digital Tachometer /8712500
PN 8712100 - Provides accurate RPM readings for
all Polaris products. 6500 RPM limit in 2-stroke three
cylinder mode. For all gasoline engines.
be
PN 8712500 - Provides RPM readings for all Polaris
products. Upper limit of 40,000 RPM with an
accuracy of ± 10. Loaded with features. For all
gasoline engines.
er
tldaptor, Alemite™ Grease Fitting
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Grease gun adaptor fits drive shaft coupler and
driveshaft bearing carrier on all PWC.
PN 2871174
rt
Siponson Insert Tool
This Tool Is Used To Install Threaded Inserts For
Sponsons
PN 2871555
4/97
1.26
GENERAL INFORMATION
Service Tips
In order to performservice work efficiently and to prevent costly errors, the technician should begin by reading the
text in this manual to become familiar with procedures before beginning. Pictures and illustrations have been
included with the text as an aid. Notes, cautions and warnings have also been included for clarification of text and
safety concerns. However, a knowledge of mechanical theory, tool use, and shop procedures is necessary to
perform the service work safely and satisfactorily. Use only genuine Polaris service parts.
&. Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will act
as an abrasive and cause damage to precision parts. Clean the vehicle before beginning service. Clean new parts
before installing.
&. Watch for sharp edges which can cause personal injury. Protect hands with gloves when working with sharp
components.
&. If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be
found. If it is necessary to tap the part into place, use a soft face hammer and tap lightly.
&. Some of the fasteners were installed with locking agents.
Use of impact drivers or wrenches will help avoid
damage to fasteners.
&. Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious
machine damage or, as in the case of steering components, can result in injury or death for the rider(s).
be
&. If a torquing sequence is indicated for nuts, bolts or screws, start all fasteners in their holes and hand tighten.
Then, following the method and sequence indicated in this manual, tighten evenly to the specified torque value.
When removing nuts, bolts or screws from a part with several fasteners, loosen them all about 1/4 turn before
removing them.
&. If the condition of any gasket or O-Ring is in question, replace it with a new one.
Be sure the mating surfaces
around the gasket are clean and smooth in order to avoid leaks.
er
&. Some procedures will require removal of retaining rings or clips.
Because removal weakens and deforms
these parts, they should always be replaced with new parts. When installing new retaining rings and clips use care
not to expand or compress them beyond what is required for installation.
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&. Because removal damages seals, replace any oil or grease seals removed with new parts.
A suitable driver
should be used when installing a new seal to prevent distortion or damage.
&. Polaris recommends the use of Polaris lubricants and greases, which have been specially formulated for the
top performance and best protection of our machines. In some applications, such as the engine, warranty
coverage may become void if other brands are substituted.
&. Grease
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should be cleaned from parts and fresh grease applied before reassembly of components.
Deteriorating grease loses lubricity and may contain abrasive foreign matter.
&.
Whenever installing batteries, care should be taken to avoid the possibility of explosion resulting in serious
burns. Always connect the positive (red) cable first and the negative (black) cable last. When working with
batteries. always wear safety glasses or a face shield and protective gloves. Battery electrolyte contains sulfuric
acid and is poisonous! Serious burns can result from contact with the skin, eyes or clothing. ANTIDOTE: External
- Flush with water. Internal - Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately. Eyes - Flush with water for 15 minutes and get prompt medical
attention.
1.27
4/96
GENERAL INFORMATION
Warranty Policy
LIMITED WARRANTY
Polaris Industries Inc., 1225 Highway 169 North, Minneapolis, Minnesota 55441-5078, gives a ONE YEAR LIMITED WARRANTY (90 days on SLX PRO 785) on all components of the Polaris personal watercraft against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by
this warranty. This warranty begins on the date of purchase. This warranty is transferrable to another consumer during the
warranty period through a Polaris dealer. There is a charge of $35.00 payable to Polaris Industries Inc.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days.
Upon receipt of this registration , Polaris will record the registration for warranty. No verification of registration will be sent to the
purchaser as the copy of the Warranty Registration Form will be the warranty entitlement. If you have not signed the original
registration and received the "customer copy", please contact your dealer immediately. NO WARRANTY COVERAGE WILL
BE ALLOWED UNLESS YOUR PERSONAL WATERCRAFT IS REGISTERED WITH POLARIS.
Initial dealer preparation and set-up of your personal watercraft is very important in ensuring trouble-free operation . Purchasing
a machine in the crate or without proper dealer set-up will void your warranty coverage.
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
This Polaris limited warranty covers all parts and components except for impeller damage caused by ingestion of rocks, sand,
or gravel or any other damage caused by operation in shallow water. The warranty also excludes any other failures that are not
caused by a defect in material or workmanship.
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This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This war"anty also does
not cover any personal watercraft that has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a
result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to
paint or finish, gel coat stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in parts, components or
personal watercraft due to fire , explosions or any other cause beyond Polaris' control.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with watercraft. In
addition this warranty does not cover stress cracks, submersion, or growth of marine organisms on hull and deck.
...J
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er
The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or replacement of any defective
materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES
AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT
OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties, so
the above limitations or exclusions may not apply to you if inconsistent with controlling state law.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY
PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED !N THIS WARRANTY. Some
states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent
with controlling state law.
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HOW TO OBTAIN WARRANTY SERVICE
If your personal watercraft requires warranty service, you must take it to a Polaris Servicing Dealer. When requesting warranty
service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO
AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however,
you may use any Polaris Servicing Dealer to perform warranty service.
Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will
contact the appropriate person at Polaris.
This warranty gives you specific legal rights , and you may also have other rights which vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect.
Engine Oil
1. Always use Polaris engine oil.
2. Never substitute or mix oil brands as serious engine damage and voiding of warranty can result.
4/97
1.28
)
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personal watercraft - Greenhulk Personal Watercraft Performance Forums

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